Ice makers and refrigeration appliances with ice makers

ABSTRACT

Ice makers and refrigeration appliances are provided. An ice maker includes a motor, and a mold body rotatably coupled to the motor and rotatable about a longitudinal axis. The mold body defines a plurality of mold compartments and a main opening providing access to each of the plurality of mold compartments. The ice maker further includes a cover body defining a recess, the recess configured to accept at least a portion of the mold body therein. The ice maker further includes a heating assembly coupled to the cover body within the recess, the heating assembly comprising a heating element embedded in a heating body. The mold body is rotatable between a first position wherein the main opening is generally enclosed by the cover body and a second position wherein the main opening is generally exposed.

FIELD OF THE INVENTION

The present subject matter relates generally to ice makers, such as for use in refrigeration appliances. In particular, the present subject matter relates to efficient, compact, low energy requiring ice makers.

BACKGROUND OF THE INVENTION

In refrigeration appliances such as refrigerator appliances (which may include freezer compartments) or stand-alone freezer appliances, several systems have been proposed for cooling of an ice maker thereof. In some systems, the ambient air within a freezer is chilled to a temperature low enough to form the ice. In other systems, known as directly cooled systems, a cooling loop for the ice maker is added to typical the refrigeration loop. The ice maker cooling loop can be routed through the mold body of the ice maker, thereby directly cooling the ice maker to increase the rate at which ice can be formed in the ice maker.

To remove formed ice cubes from typically known ice makers, the arms of a harvester (also known as a rake) may be rotated through the various mold compartments of the ice maker, sweeping the ice cubes therefrom. However, issues can arise from the use of harvesters. For example, ice cubes can become frozen to the walls of the mold compartments, and the harvester can become damaged or destroyed when encountering an ice cube that thus impedes the rotation of the harvester. Additionally, the harvesters and associated components can increase the size of the ice maker, such that the overall ice maker footprint is relatively bulky.

In some embodiments, heating elements have been added to such ice makers to slightly melt the ice cubes, encouraging detachment from the walls of the mold compartments and thus movement when contacted by the harvester. However, such heating elements typically require a relatively high amount of energy to produce the necessary heat to be successful in detaching the ice cubes. Further, harvesters are generally still required to actually remove the ice cubes from the mold compartments.

Accordingly, improved ice makers, as well as refrigeration appliances which include such ice makers, are desired. In particular, ice makers which provide efficient, compact and low energy performance would be advantageous.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In accordance with one embodiment of the present disclosure, an ice maker is provided. The ice maker includes a motor, and a mold body rotatably coupled to the motor and rotatable about a longitudinal axis. The mold body defines a plurality of mold compartments and a main opening providing access to each of the plurality of mold compartments. The ice maker further includes a cover body defining a recess, the recess configured to accept at least a portion of the mold body therein. The ice maker further includes a heating assembly coupled to the cover body within the recess, the heating assembly comprising a heating element embedded in a heating body. The mold body is rotatable between a first position wherein the main opening is generally enclosed by the cover body and a second position wherein the main opening is generally exposed.

In accordance with another embodiment of the present disclosure, a refrigeration appliance is provided. The refrigeration appliance includes a cabinet defining a fresh food chamber and a freezer chamber, and a door for accessing one of the fresh food chamber or the freezer chamber. The refrigeration appliance further includes an ice maker disposed within one of the fresh food chamber, the freezer chamber or the door. The ice maker includes a motor, and a mold body rotatably coupled to the motor and rotatable about a longitudinal axis. The mold body defines a plurality of mold compartments and a main opening providing access to each of the plurality of mold compartments. The ice maker further includes a cover body defining a recess, the recess configured to accept at least a portion of the mold body therein. The ice maker further includes a heating assembly coupled to the cover body within the recess, the heating assembly comprising a heating element embedded in a heating body. The mold body is rotatable between a first position wherein the main opening is generally enclosed by the cover body and a second position wherein the main opening is generally exposed.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 is a front view of a refrigeration appliance with its doors closed in accordance with one embodiment of the present disclosure;

FIG. 2 is a front view of the refrigeration appliance of FIG. 1 with its doors opened;

FIG. 3 is a front view of an ice maker with a mold body in a first position in accordance with one embodiment of the present disclosure;

FIG. 4 is a top view of an ice maker in accordance with one embodiment of the present disclosure;

FIG. 5 is a side perspective view of an ice maker with a mold body in a first position and a portion of a passage of a cover body cut away for illustrative purposes in accordance with one embodiment of the present disclosure;

FIG. 6 is a top perspective view of a mold body and shafts extending therefrom in accordance with one embodiment of the present disclosure;

FIG. 7 is a side view of an ice maker with a mold body between a first position and a second position in accordance with one embodiment of the present disclosure;

FIG. 8 is a side cross-sectional view of an ice maker with a mold body in a second position in accordance with one embodiment of the present disclosure; and

FIG. 9 is a bottom perspective view of a cover body and heating assembly in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIGS. 1 and 2 are front views of an exemplary refrigeration appliance 10 depicted as a refrigerator in which ice makers in accordance with aspects of the present disclosure may be utilized. It should be appreciated that refrigeration appliance 10 as shown is for illustrative purposes only and that the present disclosure is not limited to any particular type, style, or configuration of refrigeration appliance, and that such appliance may include any manner of refrigerator, freezer, refrigerator/freezer combination, and so forth.

The refrigeration appliance 10 includes a fresh food storage chamber 12 and a freezer storage chamber 14, with the chambers arranged side-by-side and contained within an outer case 16 and inner liners 18 and 20 generally molded from a suitable plastic material. In smaller refrigerators 10, a single liner is formed and a mullion spans between opposite sides of the liner to divide it into a freezer storage chamber and a fresh food storage chamber. The outer case 16 is normally formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted U-shape to form top and side walls of the outer case 16. A bottom wall of the outer case 16 normally is formed separately and attached to the case side walls and to a bottom frame that provides support for refrigerator 10.

A breaker strip 22 extends between a case front flange and outer front edges of inner liners 18 and 20. The breaker strip 22 is formed from a suitable resilient material, such as an extruded acrylo-butadiene-styrene based material (commonly referred to as ABS). The insulation in the space between inner liners 18 and 20 is covered by another strip of suitable resilient material, which also commonly is referred to as a mullion 24 and may be formed of an extruded ABS material. Breaker strip 22 and mullion 24 form a front face, and extend completely around inner peripheral edges of the outer case 16 and vertically between inner liners 18 and 20.

Slide-out drawers 26, a storage bin 28 and shelves 30 are normally provided in fresh food storage chamber 12 to support items being stored therein. In addition, at least one shelf 30 and at least one wire basket 32 are also provided in freezer storage chamber 14.

The refrigerator features are controlled by a controller 34 according to user preference via manipulation of a control interface 36 mounted in an upper region of fresh food storage chamber 12 and coupled to the controller 34. As used herein, the term “controller” is not limited to just those integrated circuits referred to in the art as microprocessor, but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein.

A freezer door 38 and a fresh food door 40 close access openings to freezer storage chamber 14 and fresh food storage chamber 12. Each door 38, 40 is mounted by a top hinge 42 and a bottom hinge (not shown) to rotate about its outer vertical edge between an open position, as shown in FIG. 2, and a closed position, as shown in FIG. 1. The freezer door 38 may include a plurality of storage shelves 44 and a sealing gasket 46, and fresh food door 40 also includes a plurality of storage shelves 48 and a sealing gasket 50.

An ice maker, as discussed herein, may be included in the freezer chamber 14, the fresh food chamber 12, or one of the doors 38, 40. For example, in the embodiment illustrated, an ice maker is disposed within an ice box 52 that is defined in door 38. A dispenser 54 may be provided in the freezer door 38 such that ice and/or chilled water can be dispensed without opening the freezer door 38, as is well known in the art. Doors 38 and 40 may be opened by handles 56 (see FIG. 1). A housing 58 may hold a water filter 60 used to filter water for the ice maker and/or dispenser 54.

As with known refrigerators, the refrigeration appliance 10 also includes a machinery compartment (not shown) that at least partially contains components for executing a known vapor compression cycle for cooling air. The components include a compressor, a condenser, an expansion device, and an evaporator connected in series as a loop and charged with a refrigerant. The evaporator is a type of heat exchanger which transfers heat from air passing over the evaporator to the refrigerant flowing through the evaporator, thereby causing the refrigerant to vaporize. The cooled air is used to refrigerate one or more refrigerator or freezer compartments via fans. Also, a cooling loop can be added to directly cool the ice maker to form ice cubes, and a heating loop can be added to help remove ice from the ice maker, as discussed below. Collectively, the vapor compression cycle components in a refrigeration circuit, associated fans, and associated compartments are conventionally referred to as a sealed system. The construction and operation of the sealed system are well known to those skilled in the art.

Referring now to FIGS. 3 through 9, an ice maker 100 is illustrated. Ice maker 100 may, for example, be utilized in a refrigeration appliance 10. In some embodiments, for example, ice maker 100 may be disposed within the freezer chamber 14, such as within an ice box and/or connected to the inner liner 20 thereof. In other embodiments, ice maker 100 may be disposed within the fresh food chamber 12, such as within an ice box disposed within the fresh food chamber 12, or within one of the doors 38, 40, such as within an ice box such as ice box 52 defined in the door 38, 40.

Ice maker 100 generally receives water, from a water source. The water is frozen to form ice cubes, which are then removed from the ice maker 100. For example, the ice cubes may be dumped into an ice bucket for holding and storage thereof until use. As discussed herein, ice makers 100 in accordance with the present disclosure may be more efficient and more compact, and may use less energy, than previously known ice making apparatus. In particular, ice makers 100 advantageously do not require harvesters to facilitate removal of ice cubes from the mold compartments of the ice makers 100. Further, heating assemblies utilized to facilitate ice cube removal are advantageously configured to use less energy to sufficiently heat the mold compartments to encourage separation of ice cubes therefrom.

As shown, ice maker 100 includes a motor 110, which may be housed within a motor housing 112. Ice maker 100 further includes a mold body 120. The mold body 120 generally accepts water therein to form ice cubes, and the ice cubes are formed within a plurality of mold compartments 122 that are defined by the mold body 120.

Mold body 120 may further be rotatable about a longitudinal axis 124. As illustrated, mold body 120 may be coupled to the motor 110. For example, a first shaft 126 may extend from the mold body 120 along the longitudinal axis 124, and may be directly coupled to the motor 110 or coupled to a shaft (not shown) of the motor 110. Operation of the motor 110 may rotate the shaft 126, which may cause rotation of the mold body 120 about the longitudinal axis 124.

Additionally, a second shaft 128 may extend from the mold body 120 along the longitudinal axis 124. The second shaft 128 may extend oppositely from the first shaft 126, and from an opposing end of the mold body 120. Second shaft 128 may stabilize the mold body 120 via contact with other components of the ice maker 100 during rotation thereof.

As discussed and as illustrated, mold body 120 defines a plurality of mold compartments 122 therein. Each mold compartment 122 may form an ice cube therein when water is frozen within the mold compartment 122. In exemplary embodiments, the mold body 120 and the mold compartments 122 thus have generally arcuate cross-sectional profiles (taken transverse to at and any point along the longitudinal axis 124). Mold body 120 may have an inner surface 132 and an outer surface 134, and the inner surface 132 may define the mold compartments 122. A main opening 136 may further define the mold compartments 122. The main opening 136 provides access to each of the plurality of mold compartments 122, and ice cubes may travel from the mold compartments 122 through the main opening 136 when exiting mold body 120. Grooves may be defined in the mold body 120, such as in the inner surface 132 thereof to collect water when the mold body 120 is rotating as discussed herein to avoid this water dripping from the body 120 into an associated ice container. These grooves may, for example, be near the main opening 136.

In exemplary embodiments, as illustrated, the mold compartments 122 may be arranged in series along the longitudinal axis 124. Alternatively, any suitable arrangement, including for example mold compartments 122 arranged in parallel and series along the longitudinal axis 124, is within the scope and spirit of the present disclosure. As shown, bulkheads 138 may generally separate and further define the mold compartments 122.

In exemplary embodiments, the mold body 120, shafts 126, 128 and bulkheads 138 may be integral with each other, such that a single component includes these various features. Alternatively, one or more of these features may be a separate component that is fastened to the others. In exemplary embodiments, the mold body 120, shafts 126, 128 and bulkheads 138 may be formed from a suitable polymer material. Alternatively, any suitable materials are within the scope and spirit of the present disclosure.

Ice maker 100 may further include a cover body 140, which may similarly be formed from a suitable polymer material or any other suitable material. Cover body 140 may have an inner surface 142 and an outer surface 144, and may define a recess 146 (which may further be defined by inner surface 142). As illustrated, recess 146 may be configured to accept at least a portion of the mold body therein. For example, the cover body 140 may similarly extend along longitudinal axis 124, and the recess 146 may have a generally arcuate cross-sectional profile. When the mold body is 120 is rotated to a first position, as illustrated in FIGS. 3 and 5, the main opening 136 may be generally enclosed by the cover body 140. For example, the main opening 136, and portions of the mold body 120, may in the first position be disposed within the recess 146, or the mold body 120 may be entirely external to the recess 146 and the main opening 136 may be slightly spaced from the recess 146 but with the cover body 140 generally preventing exposure of and access to the main opening 136 aside from between the slight gap between the mold body 120 and cover body 140. In either case, the mold body 120 in the first position may be generally exterior to the recess 146, with only small upper portions of the mold body 120 near the main opening 136 potentially being within the recess 146. When the mold body 120 is rotated to a second position as illustrated in FIG. 8, the main opening 136 is generally exposed. For example, the main opening 136, and portions of the mold body 120, may in the second position be external to the recess 146, or the mold body 120 may be entirely within the recess 146. In either case, the mold body 120 in the second position may be generally within the recess 146, with only small upper portions of the mold body 120 near the main opening 136 potentially being external to the recess 146. Further, in the first position, the main opening 136 may be an uppermost portion of the mold body 120, such that the mold body 120 is positioned to collect water and form ice cubes, while in the second position, the main opening 136 may be a lowermost portion of the mold body 120, such that the mold body 120 is positioned to allow ice cubes to fall from the mold compartments 122 through the main opening 136 due to gravity.

Ice maker 100 may further include a heating assembly 150, which may be coupled to the cover body 140 within the recess 146. In particular, the heating assembly 150 may be coupled to the inner surface 142. For example, a suitable adhesive or mechanical fasteners may be utilized to fasten the heating assembly 150 within the recess 146 and to the inner surface 142, or in exemplary embodiments the heating assembly 150 may be overmolded by the cover body 140 during formation of the cover body 140 in a suitable molding process.

Heating assembly 150 may include one or more heating elements 152 embedded in a heating body 154. Any suitable heating elements 152 may be utilized, including metal, ceramic or composite heating elements. In general, a heating element 152 in accordance with the present disclosure may convert electricity from a power source (not shown) into heat through resistive heating.

Heating body 154 may generally surround the heating elements 152 such that the heating elements 152 are embedded therein. For example, heating elements 152 may be embedded in the heating body 154 during formation of the heating body 154 in, for example, a suitable molding process. In exemplary embodiments, heating body 154 may be formed from a suitable polymer. In particular, heating bodies 154 formed from silicone are particularly advantageous.

When heating elements 152 are activated, the heat emanating therefrom may be transferred to the heating body 154 and distributed throughout the heating body 154. The heat may then emanate from the heating body 154, advantageously heating the area surrounding the heating body 154. Notably, heating assemblies 150 in accordance with the present disclosure require relatively minimal energy in order to provide the required heat as discussed herein, thus increasing the efficiency and reducing the energy requirements of the ice maker 100.

Heating body 154 may have an inner surface 156 and an outer surface 158, as illustrated. Similar to the mold body 120 and the cover body 140, the heating body may further extend along longitudinal axis 124, and have a generally arcuate cross-sectional profile. In exemplary embodiment as shown, an outer contour of the heating body 154 (defined by the outer surface 158) may generally correspond to the contour of the inner surface 142 of the cover body 140. Accordingly, when coupled to the cover body 140, the outer surface 158 may contact the inner surface 142.

Further, in exemplary embodiments, an outer contour of the mold body 120 (defined by the outer surface 134), may generally correspond to an inner contour of the heating body 154 (defined by the inner surface 156). Accordingly, when the mold body 120 is in the second position, the heating body 154, such as the inner surface 156 thereof, may advantageously generally surround, and optionally contact, the outer surface 134 of the mold body 120. In exemplary embodiments, the heating assembly 150, such as the heating elements 152 thereof, may be activated when the mold body 120 is in the second position. Heat generated by the heating elements 152 and emanating from the heating body 154 may heat the mold body 120, which may advantageously heat ice cubes within the mold compartments 122 such that the ice cubes are not frozen to the mold compartments 122 and mold body 120. Further, due to the position of the mold body 120, the ice cubes when not frozen may advantageously simply fall from the mold body 120 into an ice bucket, etc. Notably, no harvester or other apparatus is thus required to remove the ice cubes from the mold body 120.

Ice maker 100 may further include a controller 160. Controller 160 may be an independent component for ice maker 100 that is separate from other appliance controllers, such as controller 34, or may be part of or included within such controllers such as controller 34. The controller 160 may be in communication with the motor 110 and heating assembly 150, and may be configured to activate and deactivate the motor 110 and heating assembly 150 as required. For example, the controller 160 may be configured to activate the motor 110 to rotate the mold body 120 from the first position to the second position and from the second position to the first position as required Further, controller 160 may be configured to activate the heating assembly 150 when the mold body 120 is in the second position, and deactivate the heating assembly 150 when the mold body 120 is in the first position.

Ice maker 100 may additionally include various features for flowing water to the mold body 120 and compartments 122 thereof. For example, cover body 140, such as the outer surface 144 thereof, may define a liquid receptacle 170 into which water may be flowed. The water may then flow, for example, through a passage 172 defined in the cover body 140 which is in fluid communication with the receptacle 170. Water may then flow from the passage 172 into the mold compartments 122. For example, as shown, second shaft 128 of mold body 120 may define a passage 129 therethrough. The passage 129 may be in fluid communication with and between the passage 172 and the plurality of mold compartments 122. Water may thus flow from passage 172 through passage 129 into the mold compartments 122. It should be understood, however, that the present disclosure is not limited to such water supply configurations, and rather that any suitable apparatus and/or arrangements for supplying water to the mold compartments 122 is within the scope and spirit of the present disclosure.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. An ice maker, the ice maker comprising: a motor; a mold body rotatably coupled to the motor and rotatable about a longitudinal axis, the mold body defining a plurality of mold compartments and a main opening providing access to each of the plurality of mold compartments; a cover body defining a recess, the recess configured to accept at least a portion of the mold body therein; a heating assembly coupled to the cover body within the recess, the heating assembly comprising a heating element embedded in a heating body, wherein the mold body is rotatable between a first position wherein the main opening is generally enclosed by the cover body and a second position wherein the main opening is generally exposed.
 2. The ice maker of claim 1, wherein in the first position the mold body is generally exterior to the recess in the second position the mold body is generally within the recess.
 3. The ice maker of claim 1, wherein an inner surface of the cover body defines the recess, and wherein the heating assembly is coupled to the inner surface.
 4. The ice maker of claim 3, wherein an outer contour of the heating body generally corresponds to a contour of the inner surface.
 5. The ice maker of claim 1, wherein an outer contour of the mold body generally corresponds to an inner contour of the heating body.
 6. The ice maker of claim 1, wherein the heating body is formed from silicone.
 7. The ice maker of claim 1, further comprising a controller in communication with the motor and the heating assembly, the controller configured to activate the heating assembly when the mold body is in the second position.
 8. The ice maker of claim 1, wherein the cover body further defines a liquid receptacle and a passage in fluid communication with the liquid receptacle.
 9. The ice maker of claim 8, wherein the mold body further includes a first shaft and a second shaft each extending from the mold body along the longitudinal axis, the first shaft coupled to the motor, the second shaft defining a passage in fluid communication between the passage of the cover body and the plurality of mold compartments.
 10. The ice maker of claim 1, wherein the plurality of mold compartments are arranged in series along the longitudinal axis.
 11. A refrigeration appliance, comprising: a cabinet defining a fresh food chamber and a freezer chamber; a door for accessing one of the fresh food chamber or the freezer chamber; and an ice maker disposed within one of the fresh food chamber, the freezer chamber or the door, the ice maker comprising: a motor; a mold body rotatably coupled to the motor and rotatable about a longitudinal axis, the mold body defining a plurality of mold compartments and a main opening providing access to each of the plurality of mold compartments; a cover body defining a recess, the recess configured to accept at least a portion of the mold body therein; a heating assembly coupled to the cover body within the recess, the heating assembly comprising a heating element embedded in a heating body, wherein the mold body is rotatable between a first position wherein the main opening is generally enclosed by the cover body and a second position wherein the main opening is generally exposed.
 12. The refrigerator appliance of claim 11, wherein in the first position the mold body is generally exterior to the recess in the second position the mold body is generally within the recess.
 13. The refrigerator appliance of claim 11, wherein an inner surface of the cover body defines the recess, and wherein the heating assembly is coupled to the inner surface.
 14. The refrigerator appliance of claim 13, wherein an outer contour of the heating body generally corresponds to a contour of the inner surface.
 15. The refrigerator appliance of claim 11, wherein an outer contour of the mold body generally corresponds to an inner contour of the heating body.
 16. The refrigerator appliance of claim 11, wherein the heating body is formed from silicone.
 17. The refrigerator appliance of claim 11, further comprising a controller in communication with the motor and the heating assembly, the controller configured to activate the heating assembly when the mold body is in the second position.
 18. The refrigerator appliance of claim 11, wherein the cover body further defines a liquid receptacle and a passage in fluid communication with the liquid receptacle.
 19. The refrigerator appliance of claim 18, wherein the mold body further includes a first shaft and a second shaft each extending from the mold body along the longitudinal axis, the first shaft coupled to the motor, the second shaft defining a passage in fluid communication between the passage of the cover body and the plurality of mold compartments.
 20. The refrigerator appliance of claim 11, wherein the plurality of mold compartments are arranged in series along the longitudinal axis. 